Vehicle occupant restraint apparatus

ABSTRACT

A vehicle occupant restraint apparatus (10) includes an inflatable vehicle occupant restraint (12) supported on the vehicle door (16). The door (16) has a detachable inner trim panel section (32) with an outer side surface (42) that partly defines the occupant compartment (20). The apparatus further includes a source of inflation fluid (14) and a manifold (52) for directing inflation fluid from the source (14) into the restraint (12) to inflate the restraint (12). The detachable inner trim panel section (32) of the door (16) is a panel portion of the restraint (12) which moves into the occupant compartment (20) upon inflation of the restraint (12), and has an inner side surface (40) for contacting the inflation fluid directed into the restraint (12). The inner side surface (40) of the panel portion of the restraint (12) partly defines the volume enclosed within the restraint (12) when the restraint (12) is inflated.

FIELD OF THE INVENTION

The present invention relates to an inflatable vehicle occupantrestraint, and particularly relates to an inflatable vehicle occupantrestraint which is inflated upon the occurrence of a side impactcollision.

BACKGROUND OF THE INVENTION

An inflatable vehicle occupant restraint, such as an air bag, isinflated when the vehicle experiences a collision. Inflation fluid isthen directed to flow from a source of inflation fluid into therestraint to inflate the restraint. The inflation fluid expands therestraint from a stored condition to an inflated condition in which therestraint extends into the vehicle occupant compartment. When therestraint is thus inflated into the occupant compartment, it restrainsan occupant from forcefully striking parts of the vehicle.

Such an inflatable vehicle occupant restraint is concealed from theoccupant compartment when it is stored. A deployment door typicallyextends over the restraint to conceal the restraint from the occupantcompartment. The force of the inflation fluid flowing into the restraintis directed against the deployment door to open and move the deploymentdoor out of the path of the restraint when the restraint is inflated andmoved into the occupant compartment. The deployment door is normallyformed as a portion of the vehicle part in which the restraint isstored. In certain applications, the deployment door may be formed as aportion of the steering wheel, instrument panel, or vehicle door,depending upon the location of the restraint in the vehicle. If therestraint is to be inflated upon the occurrence of a side impactcollision, the restraint and the deployment door will often be locatedon a vehicle door.

SUMMARY OF THE INVENTION

In accordance with the present invention, an apparatus for restrainingan occupant of a vehicle comprises a vehicle part and an inflatablevehicle occupant restraint supported on the vehicle part. The vehiclepart has a detachable panel section with an outer side surface means forpartly defining the occupant compartment. The restraint is inflatableinto an inflated condition in which it extends into the occupantcompartment. The apparatus further includes a source of inflation fluidand a means for directing inflation fluid from the source of inflationfluid into the restraint to inflate the restraint.

The detachable panel section of the vehicle part comprises a panelportion of the restraint which moves into the occupant compartment uponinflation of the restraint. The detachable panel section of the vehiclepart, i.e., the panel portion of the restraint, has an inner sidesurface means for contacting the inflation fluid directed into therestraint. The detachable panel section of the vehicle part thus partlydefines the volume enclosed within the restraint when the restraint isin the inflated condition.

In a preferred embodiment of the present invention, the vehicle partsupporting the restraint is a vehicle door, and the panel portion of therestraint is defined by a detachable section of an inner trim panel onthe door. The restraint further has a stored air bag portion. The airbag portion of the restraint moves into a condition extending from thedoor upon inflation of the restraint. The panel portion of the restraintis fixed to the air bag portion, and moves from the door with the airbag portion upon inflation of the restraint. Since the panel portion ofthe restraint is defined by a detachable section of the inner trim panelon the door, it partly defines the occupant compartment at the door. Thepanel portion of the restraint thus functions as a deployment door whichconceals the air bag portion from the occupant compartment, and also asa portion of the restraint which moves into the occupant compartment torestrain an occupant of the vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features of the present invention will become apparent to thoseskilled in the art to which the present invention relates from readingthe following description with reference to the accompanying drawings,in which:

FIG. 1 is a schematic view of a vehicle door, a vehicle seat adjacent tothe door, and a vehicle occupant restraint apparatus comprising a firstembodiment of the present invention;

FIG. 2 is a view taken on line 2--2 of FIG. 1;

FIG. 3A is a view taken on line 3A--3A of FIG. 1;

FIG. 3B is an enlarged partial view of the apparatus of FIG. 3A, showingparts in partially actuated positions;

FIG. 4 is a view similar to FIG. 2 showing the vehicle occupantrestraint apparatus in a fully actuated condition;

FIG. 5 is a view of parts of a vehicle occupant restraint apparatuscomprising a second embodiment of the present invention;

FIG. 6 is a view of parts of a vehicle occupant restraint apparatuscomprising a third embodiment of the present invention, showing theparts in fully actuated positions;

FIG. 7 is a view of parts of a vehicle occupant restraint apparatuscomprising a fourth embodiment of the present invention, showing theparts in fully actuated positions;

FIG. 8 is a view of parts of a vehicle occupant restraint apparatuscomprising a fifth embodiment of the present invention, also showing theparts in fully actuated positions; and

FIG. 9 is schematic view of a vehicle occupant restraint apparatuscomprising a sixth embodiment of the present invention.

DESCRIPTION OF PREFERRED EMBODIMENTS

A vehicle occupant restraint apparatus 10 comprising a first embodimentof the present invention is shown schematically in FIG. 1. The apparatus10 includes an inflatable vehicle occupant restraint 12 and an inflator14. The restraint 12 and the inflator 14 are mounted on a vehicle door16 in a position adjacent to a seat 18 in the vehicle occupantcompartment 20. When the vehicle experiences an impact against thevehicle indicative of a collision, the inflator 14 is actuated. Theinflator 14 then emits a large volume of inflation fluid which isdirected into the restraint 12 to inflate the restraint 12. As therestraint 12 inflates, it moves outward from the door 16 and into theoccupant compartment 20 adjacent to the seat 18. When the restraint 12is thus inflated into the occupant compartment 20, it restrains anoccupant of the seat 18 to protect the occupant from a forceful impactwith the door 16.

As shown in FIGS. 2 and 3A, the door 16 has an outer structural panel 22and an inner structural panel 24. The door 16 further includes an innertrim panel 26 between the inner structural panel 24 and the occupantcompartment 20.

The trim panel 26 includes an armrest structure 28. The trim panel 26further has a major section 30 from which the armrest structure 28projects and a detachable section 32 above the armrest structure 28. Asshown in FIG. 3A, the major section 30 of the trim panel 26 has a sidesurface 34 which faces toward the inner structural panel 24, and has anopposite side surface 36 which faces toward the occupant compartment 20.The side surface 36 facing toward the occupant compartment 20 partlydefines the boundary of the occupant compartment 20 at the door 16. Anedge surface 38 of the major section 30 of the trim panel 26 defines anopening extending through the major section 30.

The detachable section 32 of the trim panel 26 also has a side surface40 facing the inner structural panel 24 and a side surface 42 partlydefining the boundary of the occupant compartment 20 at the door 16. Anedge surface 44 of the detachable section 32 adjoins the edge surface 38of the major section 30. The detachable section 32 further has aperipheral retainer portion 46 which overlies the inner side surface 34of the major section 30 adjacent to the edge surface 38. The detachablesection 32 thus extends entirely across, and closes, the opening definedby the edge surface 38. As indicated in FIG. 3B, the material of thetrim panel 26 is deformable sufficiently to enable the retainer portion46 to move around and past the edge surface 38 for detachment of thedetachable section 32 from the major section 30. However, the retainerportion 46 holds the detachable section 32 securely in place, as shownin FIG. 3A, until the inflator 14 is actuated.

The inflator 14 is part of an inflator module 50 which includes theinflator 14 and a manifold 52. The inflator 14 has a short, cylindricalhousing 54 with a plurality of gas outlet openings 56. The housing 54contains an ignitable gas generating material which, when ignited,rapidly produces gas for inflating the restraint 12. The gas generatingmaterial may have any suitable composition known in the art, and isignited in a known manner upon the passage of electric current between apair of lead wires 58. Although the preferred embodiments of theinvention shown in the drawings use the inflator 14 to provide gas forinflating the restraint 12, other known sources of inflation fluid couldbe used as alternatives.

The manifold 52 surrounds, but is spaced from, the gas outlet openings56 in the housing 54, and has an open end portion 60 defining a gas exitopening 62. The manifold 52 thus defines a gas flow space 64 whichcommunicates the gas outlet openings 56 in the housing 54 with the gasexit opening 62 in the manifold 52. The module 50 is fixed to the innerstructural panel 24 of the door 16 by any suitable fastening structure,such as by a weld 66, with the gas exit opening 62 being located in thespace between the inner structural panel 24 and the trim panel 26.

The restraint 12 has a portion which is defined by an air bag 70. Theair bag 70 is stored in the space between the inner structural panel 24and the trim panel 26. A first open end 72 of the air bag 70 is receivedover the open end portion 60 of the manifold 52, and is fixed to themanifold 52 by any suitable means (not shown). A second open end 74 ofthe air bag 70 is fixed to the detachable section 32 of the trim panel26 by an adhesive 76 (FIG. 3B) or an ultrasonic weld. The detachablesection 32 of the trim panel 26 thus defines a panel portion of therestraint 12 which is fixed to the air bag 70. In the first preferredembodiment of the invention, the inner side surface 40 of the detachablesection 32 extends across the second open end 74 of the air bag 70.

As shown schematically in FIG. 3A, the vehicle occupant restraintapparatus 10 further includes an electrical circuit 80. The electricalcircuit 80 includes a power source 82, which is preferably the vehiclebattery or a capacitor, and a normally open switch 84. The switch 84 ispart of a sensor 86 which senses the occurrence of a vehicle collision,such as a side impact collision in which the side of the vehicle isimpacted by an object, such as another vehicle. The sensor 86 closes theswitch 84 upon sensing the occurrence of such a side impact collision.Such a sensor is known in the art. When the switch 84 is closed, theelectrical circuit 80 directs electric current between the lead wires 58to actuate the inflator 14 by causing the gas generating material in theinflator 14 to ignite.

When the inflator 14 is actuated, the gas emitted from the inflator 14flows through the gas flow space 64 to the gas exit opening 62 and intothe restraint 12 through the first open end 72 of the air bag 70. Thegas rushes through the air bag 70 to the detachable section 32 of thetrim panel 26, and quickly reaches an elevated pressure within therestraint 12.

The pressure of the gas acting outward against the inner side surface 40of the detachable section 32 of the trim panel 26 causes the detachablesection 32 to detach from the major section 30, as shown partially inFIG. 3B. As the gas continues to flow into the restraint 12, the air bag70 inflates from the stored condition of FIG. 3A, and moves into theoccupant compartment 20 with the detachable section 32 until therestraint 12 reaches the inflated condition shown in FIG. 4. The portionof the major section 30 which is located to right of the detachablesection 32, as viewed in FIG. 3A, is sufficiently flexible to be pushedout of the path of movement of the air bag 70 by the air bag 70. Thatportion of the major section 30 thus enables the air bag 70 to move intothe space between an adjacent B-pillar and the seat 18. The majorsection 30 could further include other flexible portions about theperiphery of the detachable section 32, as needed, depending upon theparticular trim panel 26 with which the present invention is used. Therestraint. 12 is thus inflated into the occupant compartment 20 torestrain and protect an occupant of the seat 18 from a forceful impactwith the door 16. Since the inner side surface 40 of the detachablesection 32 extends across the second open end 74 of the air bag 70, thevolume enclosed within the inflated restraint 12 is defined in part bythe area of the inner side surface 40 which extends across the secondopen end 74 of the air bag 70.

In the first embodiment of the present invention described above, themajor section 30 and the detachable section 32 of the trim panel 26 abuteach other as separate parts of the trim panel 26. As shown partially inFIG. 5, a second embodiment of the present invention includes analternative trim panel 100 in place of the trim panel 26. The materialof the trim panel 100 is continuous throughout a major section 102 and adetachable section 104 of the trim panel 100. The major section 102 andthe detachable section 104 are thus joined to each other as connectedparts of the trim panel 100.

Other parts of the second embodiment of the invention are substantiallythe same as corresponding parts of the first embodiment described above.The second embodiment thus includes an inflatable vehicle occupantrestraint 106 which includes both an air bag 108 and the detachablesection 104 of the trim panel 100. The air bag 108 has an open end 110which is fixed to an inner side surface 112 of the detachable section104 by an adhesive 114. The pressure of the gas directed into therestraint 106 acts outward against the inner side surface 112 when therestraint 106 is being inflated. The volume enclosed within the inflatedrestraint 106 is thus defined in part by the area of the inner sidesurface 112 which extends across the open end 110 of the air bag 108.

The trim panel 100 further has an indented surface portion 116 whichextends around the entire periphery of the detachable section 104. Theindented surface portion 116 forms a notch which defines a stress riserin the material of the trim panel 100 that interconnects the detachablesection 104 with the major section 102. When the gas pressure actingoutward against the inner side surface 112 reaches a predeterminedelevated level, it ruptures the material of the trim panel 100 whichcomprises the stress riser. The detachable section 104 and the air bag108 are thus released for movement into the occupant compartment 20 bythe pressure of the gas directed into the restraint 106.

As an additional alternative in the design of the vehicle occupantrestraint apparatus 10, a releasable adhesive or other releasablefastening structure could be used with, or in place of, the retainerportion 46 of the detachable section 32 of the trim panel 26 in thefirst embodiment of the invention. Moreover, a score line, breakabletabs or the like could be used in place of the indented surface portion116 of the trim panel 100 in the second embodiment. In each case,however, the panel portion of the restraint would be securely held inplace on the respective door 16 until the respective inflator 14 isactuated.

In a third embodiment of the present invention, the apparatus 10includes an inflatable vehicle occupant restraint 200, which is shownpartially in FIG. 6. The restraint 200 has an air bag portion 202 and apanel portion 204. The panel portion 204 of the restraint 200 issubstantially the same as either of the alternative panel portions ofthe restraints described above. The air bag portion 202 of the restraint200 differs from the air bag portions of the restraints described abovein that the air bag portion 202 does not have an open end fixed to thepanel portion 204. Instead, the air bag portion 202 extends continuouslyover an inner side surface 206 of the panel portion 204, as shown inFIG. 6. A pair of mounting rods 208 with suitable fasteners (not shown)hold the air bag portion 202 in place against the inner side surface206. The volume enclosed within the inflated restraint 200 is thusdefined entirely by the air bag portion 202.

In a fourth embodiment of the present invention, the apparatus 10includes an inflatable vehicle occupant restraint 300, which is shownpartially in FIG. 7. The restraint 300 has an air bag portion 302 and apanel portion 304. The structure of the panel portion 304 of therestraint 300 is substantially the same as the structure of any one ofthe alternative panel portions of the restraints described above.

The air bag portion 302 of the restraint 300 is similar to the air bagportion 70 of the restraint 12, which is shown in FIG. 3A, in that theair bag portion 302 has an open end 306 which is fixed to the panelportion 304. The volume enclosed with the inflated restraint 300 is thusdefined in part by the area of an inner side surface 308 of the panelportion 304 which extends across the open end 306 of the air bag portion302. However, the air bag portion 302 of the restraint 300 differs fromthe air bag portions of each of the restraints described above in thatthe air bag portion 302 is divided into distinct tubular sections 312,314 and 316. Each of the tubular sections 312, 314 and 316 communicateswith a common air bag portion (not shown) which, in turn, communicateswith a source of inflation fluid, such as the inflator 14. Each of thetubular sections 312, 314 and 316 of the air bag portion 302 adjoins arespective section 318, 320 and 322 of the panel portion 304. Aplurality of mounting rods 310 with suitable fasteners (not shown) holdthe air bag portion 302 in place against the inner side surface 308. Themounting rods 310 also separate the tubular sections 312, 314 and 316 ofthe air bag portion 302 from each other.

When the restraint 300 is inflated as shown in FIG. 7, the inflated airbag portion 302 moves the panel portion 304 forcefully away from theinner structural panel 24. The pressure of the inflation fluid in eachof the tubular sections 312, 314 and 316 of the air bag portion 302 thusapplies a force against the respective adjoining section 318, 320 and322 of the panel portion 304. The pressure of the inflation fluid in therestraint 300 can be controlled so that the pressure differs in each ofthe tubular sections 312, 314 and 316 of the air bag portion 302. Therespective forces applied by the tubular sections 312, 314 and 316 ofthe air bag portion 302 to the adjoining sections 318, 320 and 322 ofthe panel portion 304 will differ accordingly. As a result, each of thesections 318, 320 and 322 of the panel portion 304 will contact adifferent part of the occupant's body with a different force as therestraint 300 is inflated. This arrangement enables the restraint 300 tocontact a relatively sensitive part of the occupant's body withrelatively lesser force, and to restrain the relatively sensitive partof the occupant's body with a lower fluid pressure. Likewise, therestraint 300 is able to contact a relatively stronger part of theoccupant's body with a relatively greater force and to restrain therelatively stronger part of the occupant's body with a higher fluidpressure.

In a fifth embodiment of the present invention, the apparatus 10includes an inflatable vehicle occupant restraint 400, which is shownpartially in FIG. 8. As in each of the alternative embodiments of theinvention described above, the restraint 400 has a panel portion 402which is defined by a detachable section of a door trim panel like thetrim panel 26 (FIG. 3A).

The restraint 400 further has an air bag portion 404. The air bagportion 404 of the restraint 400 is similar to the air bag portion 302of the restraint 300 shown in FIG. 7. However, the air bag portion 404differs somewhat from the air bag portion 302 in that the air bagportion 404 does not have an open end at the panel portion 402. Instead,the air bag portion 404 of the restraint 400 extends continuously overan inner side surface 408 of the panel portion 402, as shown in FIG. 8.A plurality of mounting rods 410 with suitable fasteners (not shown)hold the air bag portion 404 in place against the inner side surface408, and also divide the air bag portion 404 into distinct tubularsections 412, 414 and 416 like the tubular sections 312, 314 and 316 ofthe air bag portion 302 shown in FIG. 7.

A vehicle occupant restraint apparatus 500 comprising a sixth embodimentof the present invention is shown schematically in FIG. 9. The apparatus500 is associated with a vehicle door 502, and includes a manifold 504and an inflatable vehicle occupant restraint 506 which differ somewhatfrom the manifold 50 and the restraint 12 in the apparatus 10 describedabove. Other parts of the apparatus 500, such as an inflator 14 and anelectrical circuit 80, are substantially the same as corresponding partsof the apparatus 10, as indicated by the same reference numbers used inFIGS. 3A and 9.

The door 502 has an outer structural panel 510, an inner structuralpanel 512, and an inner trim panel 514. The trim panel 514 has a majorsection 516 and a detachable section 518. The detachable section 518extends along nearly the entire length of the major section 516 betweenthe opposite ends of the trim panel 514. The panel sections 516 and 518are otherwise substantially the same as the panel sections 30 and 32shown in FIG. 3A. The detachable section 518 is thus detachable from themajor section 516 under the influence of inflation fluid pressuredirected against an inner side surface 520 of the detachable section518.

The manifold 504 surrounds and is spaced from the gas outlet openings 56in the inflator housing 54. A plurality of first gas exit openings 522extend radially through a cylindrical side wall 524 of the manifold 504.A plurality of second gas exit openings 526 extend axially through acircular outer end wall 528 of the manifold 504. The manifold 504 issecured to the inner structural panel 512 of the door 502 by a pluralityof fasteners 530. The fasteners 530 extend through openings in acircular flange 532 at the inner end of the side wall 524.

The restraint 506 has a panel portion which is defined by the detachablesection 518 of the trim panel 514, and further has a portion which isdefined by an air bag 540. A first open end 542 of the air bag 540surrounds the inflator 14, and is secured between the inner structuralpanel 512 and the flange 532 by the fasteners 530. A second open end 544of the air bag 540 is fixed to the detachable section 518 of the trimpanel 514 by an adhesive or an ultrasonic weld.

When the inflator 14 in the apparatus 500 is actuated, the gas emittedfrom the inflator 14 flows into the restraint 506 through the first andsecond gas exit openings 522 and 526 in the manifold 504. The gas rushesthrough the air bag 540 to the detachable section 518 of the trim panel514 and quickly reaches an elevated pressure within the restraint 506.The pressure of the gas acting outward against the inner side surface520 causes the detachable section 518 of the trim panel 514 to detachfrom the major section 516 in the same manner as described above withreference to the corresponding parts of the trim panel 26 shown in FIGS.3A and 3B. As the gas continues to flow into the restraint 506, the airbag 540 inflates and moves into the occupant compartment 20 with thedetachable section 518. The restraint 506 is thus inflated into theoccupant compartment 20 to restrain and protect an occupant of the seat18 (FIG. 1) from a forceful impact with the door 502.

The restraint apparatus 500 can have any of the alternative featuresdescribed above with reference to the restraint apparatus 10. Moreover,in each of the embodiments of the invention described above, tethers arepreferably included to control the size and shape of the inflatedrestraint. Such tethers extend across the inside of an inflatablerestraint in a known manner. Also, the configuration and structure ofthe detachable panel section, which forms the panel portion of therestraint, can be varied for particular applications of the invention.For example, a detachable panel section can be covered by a trim layerwhich gives the panel portion of the restraint an appearance consistentwith the trim theme of a particular vehicle.

From the above description of the invention, those skilled in the artwill perceive improvements, changes and modifications. Suchimprovements, changes and modifications within the skill of the art areintended to be covered by the appended claims.

Having described the invention, the following is claimed:
 1. Apparatusfor restraining an occupant of a vehicle occupant compartment, saidapparatus comprising:a vehicle part having a detachable panel section,said detachable panel section of said vehicle part having an outer sidesurface means for partly defining the occupant compartment; aninflatable vehicle occupant restraint supported on said vehicle part,said restraint having a folded air bag portion which moves into anunfolded condition extending from said vehicle part into the occupantcompartment upon inflation of said restraint; said restraint furtherhaving a panel portion which comprises said detachable panel section ofsaid vehicle part, said panel portion of said restraint being fixed tosaid air bag portion to move from said vehicle part with said air bagportion; a source of inflation fluid; and means for directing inflationfluid from said source into said restraint to inflate said restraint;said restraint including means for separating said air bag portion intodistinct sections that adjoin respective distinct sections of said panelportion, said sections of said air bag portion separately applyingrespective fluid pressure forces to said respective sections of saidpanel portion upon inflation of said restraint; said sections of saidair bag portion having elongated tubular shapes, said means forseparating said air bag portion into distinct sections comprising aplurality of mounting rods which extend longitudinally between saidsections of said air bag portion.
 2. Apparatus as defined in claim 1wherein said panel portion of said restraint has an inner side surfacemeans for contacting said inflation fluid directed into said restraint,said inner side surface means thus partly defining the volume enclosedwithin said restraint when said restraint is inflated.
 3. Apparatus asdefined in claim 1 wherein said air bag portion of said restraintdefines the entire volume enclosed within said restraint when saidrestraint is inflated.
 4. Apparatus as defined in claim 1 wherein saiddetachable panel section of said vehicle part is detachable entirelyfrom said vehicle part and is moved to a location spaced from saidvehicle part upon inflation of said restraint.
 5. Apparatus as definedin claim 1 wherein said vehicle part is a vehicle door having an innertrim panel, said detachable panel section of said vehicle part being adetachable section of said inner trim panel.
 6. Apparatus as defined inclaim 1 further comprising means for sensing the occurrence of a sideimpact vehicle collision and means for causing inflation fluid to beemitted from said source in response to a sensed side impact vehiclecollision.
 7. Apparatus for restraining an occupant of a vehicleoccupant compartment, said apparatus comprising:a vehicle part having adetachable panel section, said detachable panel section of said vehiclepart having an outer side surface means for partly defining the occupantcompartment; an inflatable vehicle occupant restraint supported on saidvehicle part, said restraint having an air bag portion which moves intoan inflated condition extending from said vehicle part into the occupantcompartment upon inflation of said restraint; said restraint furtherhaving a panel portion which comprises said detachable panel section ofsaid vehicle part, said panel portion of said restraint being fixed tosaid air bag portion of said restraint to move from said vehicle partwith said air bag portion of said restraint; a source of inflationfluid; means for directing inflation fluid from said source into saidrestraint to inflate said restraint; and mounting means for holding saidair bag portion of said restraint against said panel portion in aconfiguration in which said air bag portion has sections which areseparated from each other at said panel portion by said mounting means,said sections of said air bag portion adjoining respective sections ofsaid panel portion and separately applying respective fluid pressureforces to said respective sections of said panel portion; said sectionsof said air bag portion communicating in common with said source ofinflation fluid to receive inflation fluid from said source uponinflation of said restraint.